Visor clip and method therefore

ABSTRACT

A visor clip of unitary construction is presented along with a method for manufacture. The visor clip includes an engagement portion that frictionally engages with an engagement target, which may be a sun visor in an automobile. A payload portion is designed to receive and frictionally couple to a payload, where the payload may include a number of small objects such as toothpicks. The payload portion includes a number of extended portions on one or more of the surfaces that define the payload portion. The inclusion of the extended portions provides a number of force application points that enhance the frictional engagement of the payload.

CO-PENDING APPLICATIONS

[0001] This application is a division of patent application 09/476,970,which was filed on Dec. 31, 1999.

FIELD OF THE INVENTION

[0002] The invention relates generally to a clip and more particularlyto a clip that attaches to a sun visor.

BACKGROUND OF THE INVENTION

[0003] A number of visor clips exist in the art for holding specificitems to the visor of an automobile. Many of these clips are complex andinclude a number of separate components fitted together. Such designsare costly to produce. Other designs exist that are simple inconstruction, but inadequate for holding specific types of payload.

[0004] One prior art visor clip is detailed in U.S. Pat. No. 5,489,078issued to Risley (hereinafter “Risley”). The Risley clip is specificallydesigned for holding a container of moist snuff. Although the Risleydesign is a one-piece clip, it relies on cantilever force applied to asmall portion of the base of the snuff container to provide the requiredfriction against another surface that holds the snuff container inplace. As such, the clip as disclosed by Risley only provides forceapplication to the container at a single force application area.Although this may be adequate for supporting a single large object suchas a snuff container, the clip as disclosed by Risley is inadequate forholding a number of small objects that may vary slightly in size. Forexample, the clip as disclosed by Risley does not adequately hold anumber of toothpicks.

[0005] Other prior art clips exist that are specifically designed forholding a large number of small objects such as toothpicks. One suchprior art clip is disclosed in U.S. Pat. No. 5,238,163 issued to Leachet al. (hereinafter “Leach”). Leach describes a visor clip specificallydesigned for holding toothpicks. The design as disclosed by Leachincludes a box-like structure attached to a clip where the box-likestructure includes a cover with a slit for insertion of the toothpicks.Although the design of Leach is adequate for holding toothpicks to avisor, it suffers from the disadvantage of being a multi-piece unit. Thecover, or cap, of the box-like structure of Leach is described as beingmanufactured of a different material than the box itself and the clipthat holds the assembly to the visor. As such, the manufacturing costsassociated with producing the toothpick clip as taught by Leach areundesirable. In addition, the toothpicks inserted into the toothpickholder as described by Leach are only frictionally engaged at a singlepoint within the toothpick holder (the slit of the cover), thus reducingthe stability with which the toothpicks are engaged. Furthermore, thetoothpick holder as described by Leach is only suitable for holdingobjects that fit within the narrow slot of the cover. Therefore, theusefulness of the clip as described by Leach is very restrictive.

[0006] Therefore, a need exists for a clip that is capable of engaging alarge number of small objects such as toothpicks in a stable mannerwhile providing the flexibility to be able to engage other types ofpayload as well.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007]FIG. 1 illustrates a visor clip in accordance with a particularembodiment of the present invention coupled to a sun visor;

[0008]FIG. 2 illustrates a perspective view of a visor clip inaccordance with a particular embodiment of the present invention;

[0009]FIG. 3 illustrates a side view of the visor clip of FIG. 2;

[0010]FIG. 4 illustrates a perspective view of a visor clip inaccordance with an alternate embodiment of the present invention;

[0011]FIG. 5 illustrates a side view of the visor clip of FIG. 4;

[0012]FIG. 6 illustrates a perspective view of a visor clip inaccordance with yet another embodiment of the present invention; and

[0013]FIG. 7 illustrates a side view of the visor clip of FIG. 6.

[0014] Skilled artisans appreciate that elements in the figures areillustrated for simplicity and clarity and have not necessarily beendrawn to scale. For example, the dimensions of some of the elements inthe figures may be exaggerated relative to other elements to help toimprove understanding of embodiments of the present invention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION

[0015] Generally, the present invention provides a visor clip and methodfor manufacture for such a visor clip. The visor clip as describedherein includes an engagement portion that frictionally engages with anengagement target, which may be a sun visor in an automobile. A payloadportion is designed to receive and frictionally couple to a payload,where the payload may include a number of small objects such astoothpicks. The payload portion includes a number of extended portionson one or more of the surfaces that define the payload portion. Theinclusion of the extended portions provides a number of forceapplication points that enhance the frictional engagement of thepayload. The clip described herein is of unitary construction, thussimplifying manufacturing of the clip and limiting the cost of suchmanufacture.

[0016] The invention can be better understood with reference to FIGS.1-7. FIG. 1 illustrates a clip 100 as it may be mounted on a visor 10.Although the particular embodiments illustrated in FIGS. 1-7 aredescribed as being mountable on a sun visor within an automobile, itshould be apparent to one of ordinary skill in the art that the clip maybe useful in a number of different environments and should not belimited to attachment to a sun visor. The clip 100 of FIG. 1 is shown tobe holding toothpicks 12. Note that when mounted on a sun visor 10, theclip 100 provides the toothpicks 12 in an accessible manner to a driveror passenger in the vehicle. As is illustrated, a significant portion ofthe toothpicks 12 are both visible and graspable, which can help adriver to obtain a toothpick without the need for undue attention whichis better applied to operating the motor vehicle.

[0017] A perspective view of one embodiment of a clip in accordance withthe teachings herein is illustrated in FIG. 2. The clip 100 of FIG. 2includes an engagement portion and a payload portion. The engagementportion is the portion of the clip that engages an engagement target,such as the visor of a motor vehicle. The engagement portion of the clip100 is defined by a first member 110 and a second member 120. The firstand second members are flexibly coupled in opposing positions such thata recessed region is formed between the first and second members 110 and120. The recessed region is adapted to receive the engagement target forfrictional coupling.

[0018] The frictional coupling of the engagement portion of the clip 100results from a resilient force that is generated in a direction that isgenerally normal to the direction of insertion of the engagement target.For the clip 100 of FIG. 2, the normal force will be generallyconcentrated proximate to the attachment area 114. The angle of thefirst member 110 with respect to the second member 120 and the spacingbetween the members 110 and 120 may be varied in order to adjust theamount of force applied by the first member 110 to engage the clip 100to the engagement target.

[0019] The first member 110 is flexibly coupled to the second member 120via an intermediate portion 140. The intermediate portion 140 alsoserves as a stop such that when the clip is mounted onto an engagementtarget such as a visor, the intermediate portion 140 controls how faronto the engagement target the clip is mounted. The first member 110 mayinclude an angled portion 112 that facilitates insertion of theengagement target into the recessed area formed between the first andsecond members 110 and 120. The angled portion 112 ensures that thefirst member 110 slides onto the back of a sun visor or similarengagement target smoothly.

[0020] The flexible coupling between the first member 110 and the secondmember 120 via the intermediate portion 140 allows the first member 110to flex away from the second member 120 during insertion of theengagement target. The displacement of the first member 110 from aresting position by insertion of the engagement target into the firstrecessed area results in the resilient force directed toward the secondmember 120. In one embodiment, the material used to manufacture the clip100 exhibits flexible properties that allow the first member to bedisplaced without damage or permanent alteration of the general form ofthe clip 100. However, the flexibility of the material is limited suchthat the resilience of the material is adequate to support frictionalcoupling to the engagement target. The specific materials with which theclip is preferably formed are described in additional detail below.

[0021] In one embodiment, the recessed area formed between the firstmember 110 and the second member 120 is sized to allow for theengagement portion to frictionally couple to a sun visor. As is apparentto one of ordinary skill in the art, the dimensions of the differentmembers of the engagement portion may be modified such that theengagement portion is suitable for mounting to other engagement targetshaving larger or smaller dimensions. Similarly, the general shape of theengagement portion may be altered to include multiple force applicationareas such as the force application area 114 in order to facilitatecoupling to an engagement target having a varied topography.

[0022] The payload portion of the clip 100 lies on the opposite side ofthe second member 120 with respect to the side that partially definesthe recessed region of the engagement portion. The payload portionincludes a third member 130 that is flexibly coupled to the secondmember 120 such that the third member opposes the second member in amanner that forms another recessed region. The second member 120 and thethird member 130 may be positioned such that they are generally parallelin alignment with respect to each other and a direction of insertion ofthe payload. The second member 120, which may be generally planar, isshown to have a first surface that is included in the recessed region ofthe engagement portion and a second surface that is opposite the firstsurface. The second surface of the second member 120 defines a portionof the recessed region of the payload portion.

[0023] The third member 130 also includes a first surface 132 and asecond surface. The first surface 132 lies opposite the second surfaceof the second member 120 and these two surfaces generally define therecessed region of the payload portion. The recessed region formedbetween the second surface of the second member 120 and the firstsurface 132 of the third member 130 is adapted to receive payload suchthat the payload is frictionally engaged in a non-cantilevered manner.Thus, the payload is engaged between the second and third members 120and 130 in a manner that distributes the force along both sides of thepayload.

[0024]FIG. 3 illustrates the frictional coupling of a toothpick 12 in anon-cantilevered manner. The frictional coupling of the toothpick 12 isenhanced through the use of extended portions 134 on the first surface132 of the third member 130. The extended portions 134 extend outwardfrom the first surface 132 and thus are more proximate to the secondsurface of the second member than the remaining portion of the firstsurface 132 of the third member 130. The plurality of extended portions134 provides a plurality of force application points such that thefrictional coupling of the payload is enhanced. As is illustrated inFIG. 3, force is applied to the toothpick by both of the extendedportions 134, where one of the extended portions 134 is positioneddistant from the point of insertion and the other is positionedproximate to the point of insertion.

[0025] As can be seen in FIG. 2, the extended portions 134 extend acrossthe first surface 132 of the third member 130 in a direction that isgenerally normal to the direction of insertion of the payload. In theembodiment illustrated in FIGS. 2 and 3, the extended portions aretransverse ridges, or bump-like structures that extend across the firstsurface 132 of the third member 130. The embodiments illustrated inFIGS. 4-7 illustrate alternate types of extended portions thatfacilitate the frictional coupling of the payload in a non-cantileveredmanner. These embodiments will be discussed in additional detail below.

[0026] In order to further enhance the frictional coupling of thepayload, the second surface of the second member 120 may also includeone or more extended portions 124 which extend outward and are moreproximate to the first surface 132 of the third member 130 than theremaining portion of the second surface of the second member 120. As wasthe case with the extended portions of the first surface 132 of thethird member 130, the extended portions 124 of the second surface of thesecond member 120 preferably extend across the surface in a directiongenerally normal to the direction of insertion of the payload andparallel to the direction of any extended portions on the first surface132 of the third member 130.

[0027] As can be seen in the illustration of FIG. 3, the combination ofextended portions 124 and 134 provide multiple force application pointswith respect to the payload. This results in a firm, stable coupling ofthe payload, and also permits the payload portion to engage a number ofsmall objects simultaneously, such as a group of toothpicks. Inaddition, the payload portion as illustrated is also suitable foraccepting a card, such as a scan card used for a parking garage, aspayload. The multiple force application points promote stable couplingof such scan cards, and the lack of sides on the payload portion permitoversized objects to be engaged as payload. Such oversized objects mayhave a width that is greater than the general width of each of thesecond and third members 120 and 130.

[0028] The payload portion, as partially defined by an inner surface ofthe second member 120 and an inner surface of the third member 130, maybe formed in other configurations than that illustrated in FIGS. 2 and3. FIGS. 4 and 5 illustrate clip 200 as one such alternative embodiment.The clip 200 is substantially similar to the clip 100 illustrated inFIGS. 2 and 3. The clip 200 includes a first member 210 and a secondmember 220 that define a recessed area for engaging the engagementtarget. A third member 230, which is positioned opposite the secondmember 220 defines another recessed portion for engagement of thepayload. In the embodiment illustrated in FIGS. 4 and 5, the extendedportions 235 which are shown to lie along the inner surface of the thirdmember 230 are fins which are generally thinner and more flexible thanthe transverse ridges, or bumps, 134 and 124 illustrated in FIGS. 2 and3.

[0029] In order to make the fins 235 more flexible, the clip asillustrated in FIGS. 2 and 3 may be made using a co-extrusion process.The co-extrusion processes combines two plastics during extrusion, whereone of the plastics may exhibit more rigidity and the other plastic maypossess more flexibility. Therefore, co-extrusion could be used to formthe fins 235 of a more flexible plastic than that used to form theremainder of the clip 200.

[0030] As is shown in FIGS. 4 and 5, the fins 235 provide a plurality offorce application points such that payload objects of differentconfigurations are frictionally engaged by one or more of the pluralityof fins. In another embodiment of the invention, the fins are placed onthe inner surface of the second member 220, which lies opposite thethird member 230. Although the fins aid in the frictional coupling ofthe payload regardless of which surface they are positioned upon,positioning on the third member 230 may improve the ease with which thepayload can be inserted into the recessed portion of the payloadportion.

[0031]FIGS. 6 and 7 illustrate yet another embodiment of the inventionin which the clip 300 includes a third member 330 that is non-planar.The clip 300 includes first and second members 310 and 320 that aresubstantially similar to first and second members 110 and 120 of FIGS. 2and 3. First and second members 310 and 320 define the engagementportion for coupling to the engagement target.

[0032] The payload portion of the clip 300 is different from the payloadportions of the clips 100 and 200 in that the third member 330 isnon-planar. The non-planar third member 330 is shown to include a numberof curves that achieve the same objective as the fins 235 and the clip200 and the transverse ridges 124 and 134 of the clip 100. Portions ofthe curves on the non-planar third member 330 are positioned moreproximate to the second member 320 than other portions of thenon-plainer surface 330. These extended portions 335 provide a pluralityof force application points such that the frictional engagement of thepayload is facilitated.

[0033] In order to allow the clips of FIGS. 2-7 for promotional purposesor to allow them to be decorated with one or more designs, the thirdmember of each of the embodiments may be adapted to facilitate theapplication of printing to the surface opposite the recessed areaadapted for receiving the payload. If the clip is used for attachment toa sun visor in a vehicle, this surface would be visible to thepassengers in the vehicle. In the clip 300 of FIGS. 6 and 7, the curvedsurfaces 335 may be present on the surface within the recessed area ofthe payload portion, whereas the opposite surface of the third membermay be formed to be more planar, thus enabling printing to be applied tothe planar surface. Printing may be applied through screen printing orthrough other printing means understood in the art.

[0034] In order to manufacture the clips illustrated in FIGS. 1-7, acasting die, or mold, is formed. The casting die determines the variouscharacteristics of the visor clip being manufactured, and therefore thedie must be formed in a manner such that the desirable characteristicsfor the visor clip as described with respect to FIGS. 1-7 are achieved.

[0035] The casting die is formed such that the visor clip includes anengagement portion that is adapted to couple the visor clip to a visorthrough resilient force resulting from displacement of a first memberfrom a resting position by insertion of the visor into a first recessedarea formed between the first member and a second member. The die isalso formed in a manner such that the visor clip includes a payloadportion. The payload portion includes a third member formed generallyparallel to the second member on an opposite side of the second memberfrom the first member. The third member and the second member areflexibly coupled to form a recessed area between an inner surface of thesecond member and an inner surface of the third member. The recessedarea formed between the second and third members includes extendedportions on at least one of the inner surfaces to facilitate frictionalcoupling of payload inserted into the recessed area.

[0036] Once the casting die has been formed for the visor clip, at leastone plastic material is forced into the die to form the visor clip. Thevisor clip can then be removed from the die for use. Manufacturing theclips as unitary pieces of material ensures that the clips can be massproduced in a cost-effective manner. Such cost efficient production canbe combined with the ability to add a logo or other type of printing toone or more surfaces of the clip to make the clips useful forpromotional distribution.

[0037] Various types of plastic materials may be suitable formanufacturing the visor clip. Preferably, the plastic material utilizedis somewhat heat resistant such that the visor clip will not becomedeformed while mounted to a sun visor in a motor vehicle. Additionally,the plastic material must be flexible enough to allow for thedisplacement of the various portions of the clip to enable insertion ofboth the engagement target and the payload. However, the flexibilitymust be matched by a level of resilience that ensures adequate force isapplied to facilitate the frictional couplings associated with the visorclip.

[0038] Some example plastics that may be used include acrylic,polyurethane, styrene, and vinyl. A particular acrylic that exhibitsdesirable properties for manufacture of the clips is Plexigias DR 101Acrylic. As is apparent to one of ordinary skill in the art, materialsother than plastics may be suitable for the manufacture of such clips,and the particular material may be chosen to suit the environment inwhich the clip will be used.

[0039] The step of forcing plastic material into the die to form thevisor clip may be performed using a standard extrusion process. In suchan extrusion process lengths of plastic may be extruded through thecasting die, where the lengths are typically much longer than the widthof a single clip. These plastic lengths can then be cut into a pluralityof sections, where each section is a single clip. The length of eachsection is the width of the corresponding clip, where the width is ameasurement across the clip in the same direction in which the fins 235and the extended portions 124 and 134 of the clips 100 and 200 lie.Because different payloads may be more effectively engaged using clipsof different widths, an extruded length of plastic could be cut into avariety of lengths to provide a number of different clip widths. Theextrusion and cutting of the clips in this manner is a verycost-effective means for producing the clips. Prior art clips thatinclude multiple portions or more complex designs cannot be produced insuch a simple and inexpensive manner.

[0040] In other embodiments, a co-extrusion process that includesforcing a first and second plastic material into the die may beemployed. Extrusion and co-extrusion of plastics into a casting die areprocesses that are generally known in the art. By utilizing theco-extrusion process, a first plastic material that exhibits desirableflexibility characteristics can be co-extruded along with a secondplastic material that exhibits desirable rigidity in order to form avisor clip with the overall material characteristics desired. Theco-extrusion could be used to produce lengths of plastic which are thencut to form the clips as described above with respect to a standardextrusion process.

[0041] In other embodiments, forcing the plastic material into the dieto form the visor clip may be accomplished through injection molding.Injection molding processes are also generally known in the art. Wheninjection molding is used, the clips may be individually formed suchthat no additional cutting steps are required.

[0042] In yet other embodiments, the clips may be initially formedwithout the inclusion of the extended portions in the payload portion. Athin foam material, such as a reticulated foam, with an adhesive backingcould then be inserted into the recessed area in which the payload isengaged. The adhesive backing adheres the thin foam layer to one of thesurfaces within the recessed area. In operation, the foam layer enhancesthe frictional coupling of the payload in a similar manner as the finsor other extended portions. Preferably, a long sheet of the foammaterial could be inserted prior to cutting into sections when anextrusion process is used to manufacture the clips. As is apparent toone of ordinary skill in the art, additional materials could be insertedinto the recessed area in which the payload is engaged in order toenhance the frictional engagement.

[0043] An embodiment of the invention may be practiced to provide a clipcomprising an engagement portion includes a first member and a secondmember, wherein the first and second members are flexibly coupled inopposing positions such that a first recessed region is formed betweenthe first and second members, wherein the first recessed region isadapted to receive an engagement target for frictional coupling; and apayload portion that includes a third member flexibly coupled to thesecond member such that the third member opposes the second member in amanner that forms a second recessed region, wherein the second recessedregion is adapted to receive payload such that the payload isfrictionally engaged in a non-cantilevered manner.

[0044] An embodiment of the invention may be practiced to provide theabove-described clip, wherein the first and second members are flexiblycoupled such that the first recessed region is at least partiallyexpansive upon insertion of an engagement target into the first recessedregion, and such that upon insertion, resilient force generally normalto direction of insertion of the engagement target frictionally couplesthe engagement portion to the engagement target.

[0045] An embodiment of the invention may be practiced to provide theabove-described clip, wherein the first recessed region is adapted tofrictionally couple to a sun visor.

[0046] An embodiment of the invention may be practiced to provide theabove-described clip, wherein the third member has first surface and asecond surface and wherein the second member has a first surface and asecond surface, wherein the first surface of the third member ispositioned opposite the second surface of the second member such thatthe second recessed region is partially defined by the first surface ofthe third member and the second surface of the second member, whereinthe first surface of the third member and the second surface of thesecond member are generally parallel in alignment with respect to eachother and a direction of insertion of the payload.

[0047] An embodiment of the invention may be practiced to provide theabove-described clip, wherein a plurality of extended portions of thefirst surface of the third member are more proximate to the secondsurface of the second member than a remaining portion of the firstsurface of the third member, wherein the plurality of extended portionsof the first surface of the third member enhance frictional coupling ofthe payload by providing a plurality of force application points,wherein the plurality of extended portions extend across the firstsurface of the third member in a direction generally normal to thedirection of insertion of the payload.

[0048] An embodiment of the invention may be practiced to provide theabove-described clip wherein the extended portions are fins formed onthe first surface of the third member.

[0049] An embodiment of the invention may be practiced to provide theabove-described clip wherein the third member is a non-planar memberthat includes a plurality of curves.

[0050] An embodiment of the invention may be practiced to provide theabove-described clip, wherein the extended portions are transverseridges that extend across the first surface of the third member.

[0051] An embodiment of the invention may be practiced to provide theabove-described clip, wherein at least one transverse ridge is formed onthe second surface of the second member, wherein the at least onetransverse ridge extends across the second surface in a directiongenerally normal to the direction of insertion of the payload.

[0052] An embodiment of the invention may be practiced to provide theabove-described clip, wherein a plurality of extended portions of thesecond surface of the second member are more proximate to the firstsurface of the third member than a remaining portion of the secondsurface of the second member, wherein the plurality of extended portionsof the second surface of the second member enhance frictional couplingof the payload by providing a plurality of force application points.

[0053] An embodiment of the invention may be practiced to provide avisor clip of unitary construction, comprising an engagement portionthat adapted to couple the visor clip to a visor through resilient forceresulting from displacement of a first member from a resting position byinsertion of the visor into a first recessed area formed between thefirst member and a second member, wherein the first and second membersare flexibly coupled; and a payload portion that includes a third memberformed generally parallel to the second member on an opposite side ofthe second member from the first member, wherein the third member andthe second member are flexibly coupled to form a second recessed areabetween an inner surface of the second member and an inner surface ofthe third member, wherein the second recessed area includes extendedportions on at least one of the inner surfaces of the second and thirdmembers to facilitate frictional coupling of payload inserted into thesecond recessed area.

[0054] An embodiment of the invention may be practiced to provide theabove-described visor clip, wherein the second recessed area is formedto accommodate a plurality of toothpicks as the payload.

[0055] An embodiment of the invention may be practiced to provide theabove-described visor clip, wherein the second recessed area is formedto accommodate a scan card as the payload.

[0056] An embodiment of the invention may be practiced to provide theabove-described visor clip, wherein the visor clip is unitarilyconstructed of plastic.

[0057] An embodiment of the invention may be practiced to provide theabove-described visor clip, wherein the plastic is acrylic.

[0058] An embodiment of the invention may be practiced to provide theabove-described visor clip, wherein the extended portions are transverseridges on the third member that extend across the inner surface of thethird member generally normal to a direction of insertion of thepayload.

[0059] An embodiment of the invention may be practiced to provide theabove-described visor clip, wherein the extended portions furthercomprise transverse ridges on the inner surface of the second membergenerally parallel to the transverse ridges on the inner surface of thethird member.

[0060] An embodiment of the invention may be practiced to provide theabove-described visor clip, wherein the extended portions furthercomprise fins that extend across the inner surface of the third membernormal to a direction of insertion of the payload.

[0061] In the foregoing specification, the invention has been describedwith reference to specific embodiments. However, one of ordinary skillin the art appreciates that various modifications and changes can bemade without departing from the scope of the present invention as setforth in the claims below. Accordingly, the specification and figuresare to be regarded in an illustrative rather than a restrictive sense,and all such modifications are intended to be included within the scopeof present invention.

[0062] Benefits, other advantages, and solutions to problems have beendescribed above with regard to specific embodiments. However, thebenefits, advantages, solutions to problems, and any element(s) that maycause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as a critical, required, or essentialfeature or element of any or all the claims. As used herein, the terms“comprises,” “comprising,” or any other variation thereof, are intendedto cover a non-exclusive inclusion, such that a process, method,article, or apparatus that comprises a list of elements does not includeonly those elements but may include other elements not expressly listedor inherent to such process, method, article, or apparatus.

What is claimed is:
 1. A method for manufacturing a visor clip ofunitary construction, comprising: forming a casting die for the visorclip, wherein the casting die is formed such that the visor clipincludes: an engagement portion adapted to couple the visor clip to avisor through resilient force resulting from displacement of a firstmember from a resting position by insertion of the visor into a firstrecessed area formed between the first member and a second member,wherein the first and second members are flexibly coupled; and a payloadportion that includes a third member formed generally parallel to thesecond member on an opposite side of the second member from the firstmember, wherein the third member and the second member are flexiblycoupled to form a second recessed area between an inner surface of thesecond member and an inner surface of the third member, wherein thesecond recessed area includes extended portions on at least one of theinner surfaces of the second and third members to facilitate frictionalcoupling of payload inserted into the second recessed area; and forcinga plastic material into the casting die to form the visor clip.
 2. Themethod of claim 1, wherein forcing the plastic material furthercomprises forcing a first plastic material and a second plastic materialusing a co-extrusion process.
 3. The method of claim 2, wherein thefirst plastic material is a flexible plastic and the second plasticmaterial is a rigid plastic.
 4. The method of claim 1, wherein forcingthe plastic material further comprises forcing the plastic materialusing an injection molding process.
 5. The method of claim 1, whereinthe plastic material is acrylic.
 6. The method of claim 1, wherein theplastic material is taken from a group of materials that includespolyurethane, styrene, and vinyl.
 7. The method of claim 1, whereinforcing the plastic material further comprises extruding the plasticmaterial.
 8. The method of claim 1, wherein forcing the plastic materialfurther comprises forcing the plastic material through the casting dieto form a length of plastic material and cutting the length of plasticmaterial into a plurality of sections to form a plurality of visorclips.